Exterior panel attachment

ABSTRACT

An exterior panel includes a plurality of slots extending across the width of the panel. A plurality of nailing holes resides above the slots into which nails are driven to secure the panel to the surface of a building structure. The slots permit expansion and contraction of the panel relative to the surface of the building structure.

BACKGROUND OF INVENTION

[0001] The present invention relates to an exterior panel that is capable of being secured to a building structure while permitting expansion and contraction of the panel.

[0002] Exterior panels for covering the surface of a roof or building structure are well known in the art. These panels can be formed of metal, aluminum, plastic, wood and various other materials, and are exposed to varying environmental conditions, including temperature variations throughout the seasons. Such panels are secured to a surface, such as a roof deck. The surface is typically made from wood panels, such as oriented strandboard (OSB). Because the panels and roof deck are constructed from materials having a different coefficient of thermal expansion (CTE), the panels may deform or buckle during thermal cycles unless some provision is provided for the relative thermal expansion therebetween.

[0003] Accordingly, such panels described in the prior art typically have at least one section with a plurality of laterally extending nailing slots adjacent the top edge of the panel for securing each individual panel to the roof deck, and the panels are intended to be loosely secured to the roof deck by driving a nail partially into the rood deck through the slot, so any panel expansion is accommodated by relative movement of the panel to the nail within the slot. The panel also includes a clip provided adjacent the nailing slots. The clip comprises part of an interlocking assembly, wherein the upwardly projecting open clip is adapted to engage and cooperate with a downwardly projecting flange formed on the bottom edge of an overlaid second panel.

[0004] Thus, a course of the panels with the upwardly projecting clip is secured to the roof deck by nailing through the slots as described above. A second course of panels is secured by engaging the flange on each panel of the second course to a clip on at least one of the panels of the first course. The panels of the second course are then nailed to the roof deck in a manner similar to the first course and the pattern is repeated over the entire roof deck.

[0005] Substantial difficulty has been encountered with this design, particularly with panels constructed of thermoplastic material. In typical thermoplastic roofing panels, the plurality of laterally-extending nailing slots are provided to permit lateral expansion and contraction of the panel relative to the roof deck as described above. When installed properly, the nails are intended to be partially driven into the roof deck “loose nailed”, thus creating a space between the panel and the nail head (the panel is not tightly sandwiched between the nail head and the roof deck). This “loose nailing” permits expansion of the panel relative to the roof deck, as the panel will expand and the slot will permit relative movement of the panel in the lateral dimension relative to the nails that secure the panel to the roof deck. However, during a typical installation process, a pneumatic nail gun is used to facilitate quick installation of the roof. As a result, the nails are often driven completely into the roof deck, which, in turn, does not permit expansion of the panel. Even if the panels were nailed to the roof deck by hand, it requires a considerable amount of time, skill, care and effort to drive the nails only partially into the roof deck.

[0006] Numerous patents address the importance of panel expansion and contraction and ease of installation. U.S. Pat. No. 5,729,946 illustrates a siding panel that includes a nailing strip made of flexible material, such as rubber or fabric, that is attached to the siding panel. Nails or staples are driven through the flexible nailing strip to attach the panel to a surface. Adhesives may also be used on the nailing strip to affix the panel to the surface.

[0007] U.S. Pat. No. 5,979,135 shows a siding panel having a polyester yarn fabric as a nailing edge. The warp yarn is woven into a solid band and the weft yarn is woven to form a series of loops beneath the solid band. The weft yarn loops are laminated into the top edge of the siding panel. A nail is driven through the solid band of the fabric to attach the panel to a surface. Because this design includes a separate piece of fabric to accommodate expansion, the attachment of such a separate nailing edge requires additional steps in the manufacturing process (including lamination), this adding to the cost, and potentially affecting performance, of such a panel.

[0008] U.S. Pat. No. 5,388,381 illustrates an interlock assembly for adjoining adjacent building panels. The assembly includes a continuous wall panel having a lip and a groove for receiving a second non-continuous panel, which also has a groove to receive the lip of the continuous panel. The panels are essentially “snapped” together and are tightly interlocked near the bottom and/or sides of the panel. The spaces formed on either side of the interlocked portion of the panels permit expansion and contraction of the panel relative to the adjacent panel. The top end of each such panel is secured to the structure by nailing the panels to the structure through the typical slotted holes (5) as described above.

[0009] U.S. Pat. No. 5,685,117 shows a metal roofing shingle system including shingles and a fastening strip. The bottom edge of the shingle has an underturned flange having a hook. The “117 patent illustrates two embodiments of a fastening strip, the first of which having a top flange and a flat bottom flange connected by a living hinge. In this embodiment, the bottom flange of the fastening strip is nailed to a roof deck and a hook on the top flange of the fastening strip engages the hook on the bottom edge of the shingle. The top edge of the lower shingle is trapped under the top flange 36 of the fastening strip and secured to the deck by the nail driven through the fastening strip and the top edge of the lower shingle. In this design, it appears that the fasteners are “loose nailed” into the roof deck (FIGS. 10 and 12), and therefore these suffer the same installation problems mentioned above with respect to the inability to reliably secure such panels. In FIG. 16, either the fastener is not completely secured, or the fastener is driven through the lower course of roof panels, and there is no apparent provision for expansion of the panel in that embodiment. Thus, in that embodiment, if the panel expanded relative to the roof deck (especially if one were to use a thermoplastic panel), the panel may deform unacceptably under thermal cycling.

[0010] One problem with past two-piece panel designs is that they still require the fasteners to be “loose nailed” into the roof deck, or if not “loose nailed”, the designs do not adequately provide for expansion of the panel. Additionally, because some designs include more than one piece to the panel, manufacturing costs as higher. For example, panels described in U.S. Pat. No. 5,729,946, U.S. Pat. No. 5,979,135 and U.S. Pat. No. 5,857,303 (described above) include rubber or fabric on the nailing edge, which is costly to manufacture, as a separate piece must be glued on or fitted into the panel.

[0011] There is a need to provide an exterior building panel which provides for relative thermal expansion and which is easy to install and inexpensive to manufacture.

[0012] SUMMARY OF INVENTION

[0013] The present invention comprises an exterior panel having an upper portion and a lower portion. A plurality of slots, or other expansion provision extends across the width of panel in, or adjacent to, the upper portion.

[0014] Accordingly, it is an object of the present invention to provide an exterior panel that can be tightly nailed to a surface to allow for the expansion and contraction of the panel relative to the surface to which it is nailed.

[0015] It is another object of the present invention to provide an exterior panel which is less costly to manufacture and easy to install.

[0016] The foregoing and other advantages of the invention will become apparent from the following disclosure in which one or more preferred embodiments of the invention are described in detail and illustrated in the accompanying drawings. It is contemplated that variations in procedures, structural features and arrangement of parts may appear to a person skilled in the art without departing from the scope of or sacrificing any of the advantages of the invention.

SUMMARY OF INVENTION

[0017] The present invention comprises an exterior panel having an upper portion and a lower portion. A plurality of slots, or other expansion provision extends across the width of panel in, or adjacent to, the upper portion.

[0018] Accordingly, it is an object of the present invention to provide an exterior panel that can be tightly nailed to a surface to allow for the expansion and contraction of the panel relative to the surface to which it is nailed.

[0019] It is another object of the present invention to provide an exterior panel which is less costly to manufacture and easy to install.

[0020] The foregoing and other advantages of the invention will become apparent from the following disclosure in which one or more preferred embodiments of the invention are described in detail and illustrated in the accompanying drawings. It is contemplated that variations in procedures, structural features and arrangement of parts may appear to a person skilled in the art without departing from the scope of or sacrificing any of the advantages of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0021]FIG. 1 is a plan view of the preferred embodiment of an exterior panel according to the present invention.

[0022]FIG. 2 is a side view of a second embodiment of an exterior panel according to the present invention.

[0023] In describing preferred embodiments of the invention, which are illustrated in the drawings, specific terminology is resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

[0024] Although preferred embodiments of the invention are herein described, it is understood that various changes and modifications in the illustrated and described structure can be affected without departure from the basic principles that underlie the invention. Changes and modifications of this type are therefore deemed to be circumscribed by the spirit and scope of the invention, except as the same may be necessarily modified by the appended claims or reasonable equivalents thereof.

DETAILED DESCRIPTION

[0025] Referring to the drawings, in FIG. 1, the illustrated preferred embodiment, exterior panel 2 includes an upper portion 1, a lower portion 3, nailing holes 4, and a provision to accommodate expansion of the panel, the expansion provision in a preferred embodiment comprising slots 6 and ribs 8. The upper portion 1 of the exterior panel include slots 6 and ribs 8 which define a “living hinge”, which comprises the provision in the panel 2 that permits expansion and contraction of the lower portion of the panel 3 when the panel is installed on a surface and expands relative to the surface, such as a roof deck. In a preferred embodiment, the panel 2 comprises a thermoplastic sheet as known in the art. In a preferred embodiment, the panel comprises a single unitary piece made from a single sheet of material which is extruded or otherwise manufactured, then the piece is thermoformed or otherwise shaped into the shape of the exterior panel, forming desired contours on the upper 1 and lower 3 portions. The slots 6 are punched or otherwise integrally formed in the unitary panel (i.e. not in a separate piece). Alternatively, the panel could be injection molded or otherwise manufactured to include the shapes and slots integrally formed therein. The slots 6 may be formed in the upper portion 1 or at the top of the lower portion 3, or between the two portions.

[0026] An exterior panel of the present invention is preferably installed to a roof as follows: a starter strip is installed adjacent the bottom edge of a roof deck along the width of the roof deck. The starter strip is generally known and not described in detail, but comprises an upstanding clip for engaging a flange on a first course of the panels in a known manner. As is also known to one skilled in the art, the roof deck is preferably covered with a material, such as roofing felt or the like, under the panels.

[0027] A first course of panels is installed along the lower edge of the roof deck by first engaging a downstanding flange on the lower surface of each panel (adjacent the bottom edge thereof) to the clip on the starter strip. Each panel is then “hard nailed” to the roof deck through the nailing holes 4. “Hard nailed” in this application refers to the fact that the installer need not leave a gap between the nail head and the panel, as opposed to the prior art, where the nails are intended to be driven only partially into the roof deck to leave such a gap, and accordingly the panel is compressed between the nail head and the roof deck. A second course of panels includes a downstanding flange and engages an upstanding clip on the first course of panels as described above. The second course of panels is similarly hard nailed to the roof deck so that a portion of the underside of the second panel abuts the exposed surface of the first panel. Successive courses of panels are installed in this same manner until the entire surface of the roof deck is covered. Each successive course covers the attachment and expansion provision of the underlying course of panels.

[0028] Because the panels are hard nailed to the roof deck, installation is simple, fast, and the panel is securely attached to the deck. When the panels are subject to heat, as in the summer months, the panel 2 expands relative to the roof deck due to differing temperatures and differing CTE between the deck and panels. Slots 6 and ribs 8 and permit the panel 2 to expand relative to the roof deck; i.e., while the panel expands, the ribs and the slots permit local deformation of the panel to accommodate the relative expansion.

[0029] Another alternative design (not shown) for the expansion provision in such a panel, includes slots and ribs provided adjacent or between the nailing holes. In a further alternate embodiment (not shown), a plurality of tabs are provided, the tabs extending vertically above the panel and including a nailing hole, thus creating a discontinuous nailing flange. In this embodiment, the slots and ribs are completely eliminated; thus creating nailing tabs with open spaces between each tab. The tabs are deformable, such that the panel is permitted to move relative to the roof deck through the deformation of the tabs during relative thermal expansion. The tabs may also include relief slots or such to accommodate the expansion.

[0030] Each of these embodiments may include construction of the nailing flange which is substantially weakened, and therefore may require a reinforcement material or the use of materials which differ from the base material of the panel, such that the flange is strengthened by the reinforcement or the use of different materials to overcome the weakening of the panel due to the expansion provision.

[0031]FIG. 2 depicts another embodiment of the present invention utilizing a two-piece construction. The exterior panel 10 includes a nailing strip 14 and a lateral expansion provision 18. The lateral expansion provision 18, slidably engages the nailing strip 14 to the exposed portion 12 via a “j-type” attachment (or any similar such interlocking/sliding interface). One end of the j-type attachment is integrally formed in each of the nailing strip 14 and the exposed portion 12.

[0032] Installation of the panel 10 involves hard nailing the nailing strip 14 to a surface, i.e., a roof deck. The exposed portion 12 of the panel 10 is slidably attached nailing strip 14 by means of the lateral expansion provisional 18, and therefore will accommodate relative thermal expansion between the panel 10 and the roof deck as described above with reference to FIG. 1. Preferably, the manufacturer assembles the nailing strip 14 to the exposed portion 12 and the installer installs the panel 10 as a single unit. Alternatively, the installer may install the nailing strip 14 and slide or snap the exposed portion 12 to the strip 14.

[0033] Preferably, this embodiment includes an interlocking clip and flange between successive courses as also described above with reference to FIG. 1. Once the second panel is interlocked with the lower course, the nailing strip 14 of the second exterior panel is nailed to the roof deck. The exposed portion of the second exterior panel is slidably engaged to the lateral expansion provision of the nailing strip of the second panel so that a portion of the underside of the exposed portion of the second panel abuts the exposed surface of the first panel. An adjacent shingle covers the area where the sheets are engaged and the lateral expansion provision. Successive thermoplastic panels are installed in this same manner until the entire surface of the roof deck is covered.

[0034] The exposed portion 12 of the exterior panel 10 is able to expand and contract relative to the roof deck because of the “J-type” attachment of the nailing strip 14 and the exposed portion 12. The attachment may allow for a space 17 to be formed between the nailing strip 14 and the lateral expansion provision 18 of exposed portion 12. The sliding engagement provides for the exterior panel 10 to expand and contract relative to the roof deck.

[0035] The exterior panels 2 and 10 may be made of any material but are preferably constructed of polyvinyl chloride or “PVC” which is typically employed because of its superior resistance to weathering (described in U.S. Pat. No. 5,987,838 and herein incorporated by reference). PVC resins can be alloyed with other polymers, such as ABS (acrylonitrile-butadiene-styrene) resins, acrylic, polyurethane, and nitrile rubber to improve impact resistance, tear strength, resilience, or processability. They can be produced in either rigid or flexible compositions, and they can be pigmented to almost any color.

[0036] Alternatively, the nailing strip 14 of exterior panel 10 may be constructed of a more resilient material than that of exposed portion 12. Various plasticizers, fillers, stabilizers, lubricants, and impact modifiers, PVCs can be compounded to be flexible or rigid, tough or strong, to have high or low density, or to have any of a wide spectrum of physical properties or processing characteristics. Furthermore, the lower portion 3 of exterior panel 2 may be constructed of a more rigid material and the upper portion 1 constructed of a more flexible material. Both designs permitting expansion or contraction in view of the resiliency of the nailing portions.

[0037] Other methods (not shown) may be used to allow for expansion and contraction of the thermoplastic panel relative to the roof deck. For example, another variation of the two-piece thermoplastic panel design of FIG. 2 may be used. In one such alternative embodiment, a nailing strip 14 is hard-nailed to the deck while a second section is secured, below the nail, to the first section by a VELCRO attachment, glue (i.e. non hardening, such as silicone, adhesive) or any other suitable attachment means.

[0038] Furthermore, the nailing strip 14 may be made from a material with a coefficient of thermal expansion (CTE) similar to the roof deck (including for example a pressed wood product), and therefore would not experience significant relative contraction. Additionally, the first sheet may comprise a material with properties different than the material of the second sheet, such as having more strength (e.g. extruded aluminum or formed sheet metal) and/or resiliency and/or may include reinforcements). Such a construction would not permanently deform if hard nailed to the roof deck and experienced relative expansion (therefore it would not bow between fasteners). Likewise, since the nailing strip 14 is not visible, the coloration of such first panel is not material.

[0039] Alternatively, holes or slots may be placed around the nailing holes of the thermoplastic roofing panel. The holes permit expansion and contraction in the area of the nailing hole. Although it has been found that holes close to the nailing holes may result in cracking of the panel during expansion and contraction, reinforcement of the holes with rubber, fabric, or plastic may prevent cracking of the thermoplastic panel and still permit the panel to expand/contract relative to the roof deck. Alternatively, Or the portion of the panel adjacent the nailing portion may comprise a reinforced, elastomeric, or stronger material. Additionally, the separate nailing strip may include some relief around the nail holes as described with reference to the first embodiment, if relative expansion between the strip and deck needs to be accommodated.

[0040] Any of the panels described above may also be applied as siding or other such material used on a building structure. The siding would be applied in a similar manner as the roofing panel.

[0041] It is possible that changes in configurations to other than those shown could be used but that which is shown is preferred and typical. It is therefore understood that although the present invention has been specifically disclosed with the preferred embodiment and examples, modifications to the design concerning sizing and shape will be apparent to those skilled in the art and such modifications and variations are considered to be equivalent to and within the scope of the disclosed invention and the appended claims. 

1. an exterior panel comprising: a) an upper portion having a width; b) a lower portion; and c) a plurality of slots extending across the width of said upper portion, wherein said upper portion is fixedly securable, and wherein said plurality of slots permit relative movement of said lower portion to said upper portion.
 2. The exterior panel of claim 1 wherein the exrior panel is a roofing shingle.
 3. The exterior panel of claim 2 wherein the roofing shingle is a thermoplastic roofing shingle.
 4. The exterior panel of claim 1 wherein the upper portion and lower portion comprise an integral unitary member and said slots are integrally formed in said unitary member.
 5. The exterior panel of claim 1 wherein said upper portion further comprises a nailing flange with a plurality of holes for securing said panel to a structure, and wherein said slots are formed adjacent said holes.
 6. The exterior panel of claim 5 wherein said slots are formed below said holes at the bottom of said nailing flange and above said lower portion.
 7. The exterior panel of claim 1 wherein the upper portion is constructed of a material more resilient than said lower portion.
 8. An exterior panel comprising: a) a nailing strip constructed of a first material; b) an exposed portion constructed of a second material; and c) a lateral expansion provision provided between said nailing strip and said exposed portion, said lateral expansion provision being formed as an integral member to at least one of the nailing strip and the exposed portion.
 9. The exterior panel of claim 8 wherein said first material and said second material are identical.
 10. The exterior panel of claim 8 wherein the first material is more reilient than the second material.
 11. The exterior panel of claim 8 wherein said lateral expansion provision comprises a strip of material formed integrally within one of the nailing strip or the exposed portion, said strip having a plurality of slots formed therein.
 12. The exterior panel of claim 8 wherein said lateral expansion provision comprises a j-type attachment, wherein one half of said j-type attachment is integrally formed in each of said nailing strip and exposed portion.
 13. The exterior panel of claim 8 wherein said exposed portion and said nailing strip are slidably engaged.
 14. The exterior panel of claim 8 wherein said nailing strip comprises nailing holes and said nailing strip is hard nailed to a structure.
 15. The exterior panel of claim 1 wherein said nailing strip comprises a plurality of slots formed around the nailing holes.
 16. The exterior panel of claim 8 wherein said exterior panel is a roofing shingle.
 17. The exterior panel of claim 16 wherein said roofing shingle is a thermoplastic roofing shingle.
 18. The exterior panel of claim 16 wherein said thermoplastic roofing shingle is hard nailed to a roof deck.
 19. The exterior panel of claim 18 wherein said roof deck has a first coefficient of thermal expansion and the nailing strip has a second coefficient of thermal expansion similar to that of the roof deck.
 20. The panel of claim 8 wherein the expansion provision comprises a plurality of slots formed in one of the nailing strip and exposed portion.
 21. The panel of claim 8 wherein the nailing strip, exposed portion, and lateral expansion provision comprise a unitary member.
 22. The panel of claim 21 wherein the expansion provision comprises a plurality of slots formed in one of the nailing strip and exposed portion.
 23. A method for making an exterior panel comprising: a) forming a nailing strip; b) forming an exposed portion; and c) forming a lateral expansion provision between said nailing strip and said exposed portion, said lateral expansion portion being formed as an integral member to at least one of the nailing strip and the exposed portion.
 24. The method of claim 23 wherein said lateral expansion provision comprises a j-type attachment, wherein one half of the j is integrally formed in each of said nailing strip and said exposed portion.
 25. The method of claim 23 wherein said exposed portion and said nailing strip are slidably engaged.
 26. The method of claim 23 further comprising the steps of forming a plurality of nailing holes and forming a plurality of slots formed around the nailing holes.
 27. The method of claim 23 wherein said exterior panel is a roofing shingle.
 28. The method of claim 27 wherein said roofing shingle is a thermoplastic roofing shingle.
 29. The method of claim 28 further comprising the step of hard nailing said thermoplastic roofing shingle to a roof deck.
 30. The method of claim 29 wherein said roof deck has a coefficient of thermal expansion and said nailing strip has a coefficient of thermal expansion similar to that of the roof deck. 